Assembling the system

Abstract

The purpose is to reduce the risk of defective products flowing out and improve the efficiency of assembly operations. An assembly system (10) according to one embodiment of the present invention is used to assemble a finished product while sequentially arranging and fixing multiple types of components to a workpiece. The assembly system (10) comprises: a collaborative robot (20) that cooperates with an operator (100); an identification information reading unit (27) that reads identification information displayed on a component arranged on the workpiece; and a control device (70) that determines the correctness of the type of component arranged on the workpiece based on the read identification information, and controls the collaborative robot according to the correctness result.

Description

Technical Field

[0001] The invention relates to an assembly system. Background Art

[0002] As the labor force decreases, robots are being introduced into the manufacturing field. A robot system is disclosed in which a robot and an operator coordinate to perform manufacturing-related operations (e.g., Patent Document 1). In such a robot system, in order to prevent the outflow of defective products, it becomes particularly important to inspect the manufactured products.

[0003] In the past, in the assembly process of a product, in order to confirm the type of installed parts or the assembly status of the parts, the operator performed a visual inspection according to a pre-specified process. However, the operator's visual inspection has the following problems: because the inspection time is added to the normal assembly operation time, the operation time in one process becomes longer, and the quality of the visual inspection varies due to the operator's proficiency, physical condition, etc. By introducing a dedicated inspection device to replace the operator's visual inspection, the risk of defects such as deviations in inspection quality, incorrect installation of parts, and installation errors can be reduced. However, in this case, a new dedicated inspection process needs to be set up in the middle of the assembly operation or after the installation is completed, which becomes the main reason for the reduction in the overall assembly operation efficiency.

[0004] Prior art literature

[0005] Patent Literature

[0006] Patent Document 1: Japanese Patent Application Publication No. 2019-209401 Summary of the invention

[0007] Problem that the invention aims to solve

[0008] Therefore, it is desirable to reduce the risk of outflow of defective products and improve the work efficiency of assembly work.

[0009] Means used to solve problems

[0010] An assembly system of one mode of the present disclosure is a system for assembling a finished product while sequentially arranging and fixing multiple types of components to a workpiece. The assembly system comprises: a collaborative robot that cooperates with an operator; an identification information reading unit that reads identification information displayed on the component arranged on the workpiece after arrangement and before fixing; a photographing unit that photographs the component arranged on the workpiece after arrangement and before fixing; and a control device that determines the type of the component arranged on the workpiece and the correctness of the configuration state based on the read identification information and the configuration state including the position of the component and the orientation of the component obtained from the image of the photographed component, and controls the collaborative robot according to the correctness result, and controls the collaborative robot to fix the component when it is determined that the type of the component arranged on the workpiece and the configuration state are correct; the operator is responsible for the configuration of the component, and the collaborative robot is responsible for the fixing of the component arranged by the operator, and the control device allows the collaborative robot to start the fixing of the component when it is determined that the type of the component arranged on the workpiece and the configuration state are correct.

[0011] Effects of the Invention

[0012] According to this aspect, the risk of defective products flowing out can be reduced and the work efficiency of the assembly work can be improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 It is a plan view showing the configuration of the assembly system according to the present embodiment.

[0014] Figure 2 yes Figure 1 This is the system configuration diagram of the assembly system.

[0015] Figure 3 It is shown in Figure 2 A diagram of an example of a product management table stored in a storage device.

[0016] Figure 4 It is shown in Figure 2 Figure 1 shows an example of a confirmation screen displayed on the touch screen display of .

[0017] Figure 5 It shows that the Figure 1 A process diagram of the work flow of assembly operations of an assembly system.

[0018] Figure 6 It is used to illustrate Figure 5 Supplementary illustration of process 1 to process 4.

[0019] Figure 7 It is used to illustrate Figure 5 Supplementary illustration of steps 5 to 7. DETAILED DESCRIPTION

[0020] Hereinafter, the assembly system of the present embodiment will be described with reference to the drawings. In the following description, the same reference numerals are given to components having substantially the same function and structure, and repeated description will be given only when necessary.

[0021] (Overview of the assembly system)

[0022] The assembly system of this embodiment is a system in which an operator and a cooperative robot cooperate to perform assembly work of a finished product. The finished product here refers to the final object assembled by the assembly system, and does not refer to the final product sold.

[0023] One of the features of the assembly system of the present embodiment is that, in the multiple operation processes of assembling the finished product, the collaborative robot can be responsible for the work of confirming the type of components and fixing the components to the workpiece (base component). By making the collaborative robot responsible for simple operations that the collaborative robot is good at and making the operator responsible for more complicated operations, the respective operation times are averaged, thereby improving the overall manufacturing efficiency and suppressing quality deviations. For example, the collaborative robot is responsible for the work of confirming components that is time-consuming for the operator and the work of fixing components that cause many errors and put a heavy physical burden on the operator. In the overall process, the operator is responsible for the configuration of components on a more complicated workpiece using a template or a fixture.

[0024] (Assembly system configuration)

[0025] The assembly system of this embodiment is configured to correspond to the assembly line production method. Multiple operators and multiple collaborative robots are arranged at predetermined positions on the side of the conveyor, and perform predetermined operations on the workpieces transported by the conveyor to assemble the finished product. The assembly system is configured so that one operator is responsible for one operation process. However, it is also possible to configure one operator to be responsible for multiple processes, or to configure one operator and one collaborative robot to collaborate to assemble the finished product.

[0026] like Figure 1As shown, the assembly system 10 has a conveyor 30. On one side across the conveyor 30, a plurality of, here three, cooperative robots 20A, 20B, and 20C are arranged along the conveyor 30, and screw feeders 80A, 80B, and 80C are arranged near the three cooperative robots 20A, 20B, and 20C to supply screws to the cooperative robots 20A, 20B, and 20C. The screw feeder 80 supplies screws to the cooperative robot 20 according to instructions from the cooperative robot 20. On the other side across the conveyor 30, standing positions of a plurality of operators 100A, 100B, 100C, 100D, 100E, 100F, and 100G are determined. The conveyor 30 is equipped with a touch screen 60 and a plurality of completion buttons 37A, 37B, 37C, 37D, 37E, 37F, and 37G. The plurality of completion buttons 37A, 37B, 37C, 37D, 37E, 37F, and 37G are arranged at positions corresponding to the standing positions of the plurality of workers 100A, 100B, 100C, 100D, 100E, 100F, and 100G. In the following description, when no special distinction is required, they are described as the collaborative robot 20, the completion button 37, and the worker 100.

[0027] (Integrated control device 70)

[0028] The integrated control device 70 performs integrated control on the assembly system 10. Figure 2 As shown, the integrated control device 70 includes a processor 71. The processor 71 is connected to a storage device 73 and a communication device 75 via a data control bus.

[0029] The storage device 73 stores a plurality of assembly programs for controlling the conveyor device 30 and the cooperative robot 20 according to the finished product to be assembled. The assembly program is a program that records the action timing of the cooperative robot 20, the reading action of the identification information by the code reader 27, and the driving timing of the conveyor device 30. The processor 71 executes the assembly program, thereby causing the cooperative robot 20 and the conveyor device 30 to perform predetermined actions. The assembly program is associated with a component type determination program.

[0030] The component type determination program is a program for determining whether the type of the component arranged on the workpiece is correct or not based on the identification information read by the code reader 27. By executing the component type determination program by the processor 71, for example, the component specification (component code) of the correct type of component provided from the external control system 90 is used as a reference code, and the component code determined based on the identification information of the component arranged on the workpiece is compared with the reference code, thereby determining whether the component arranged on the workpiece is correct or not.

[0031] The storage device 73 stores data of a finished product management table in which identification information of the workpiece read by the code reader 27 is registered. Figure 3 As shown, in the finished product management table, the equipment number, product type, base number, component specification, and component ID are associated with the manufacturing date and time. For example, the manufacturing date and time shows the date and time when the finished product is manufactured, for example, it is registered as the date and time when the identification information is last read. The equipment number is a change that shows the equipment that manufactures the finished product, for example, it is registered as the production line number entered by the operator on the setting screen displayed on the touch screen 60. The product type shows the type of the finished product, for example, it is registered as the name of the type of the finished product entered by the operator on the setting screen displayed on the touch screen 60 or a code corresponding to its name. The base number is a serial number used to identify the finished product, and in this embodiment, it is registered as the reading result of the base identification information attached to the base as the workpiece. The component specification shows the type of the component, and the reading result of the identification information recorded on the component is registered. The component ID is a serial number used to identify the components one by one or a batch number used to identify the components in batches, and the reading result of the identification information recorded on the component is registered.

[0032] By simply reading the identification information recorded on the workpiece and parts through the code reader 27, the finished products can be managed individually through the finished product management table as described above. Therefore, there is no need for manual operations such as inputting inspection tables by the operator, and inspections can be performed simply, and it is easy to determine when and where defective products were produced.

[0033] The integrated control device 70 is connected to the cooperative robot 20, the touch screen 60, and the external control system 90 in a communicable manner via the communication device 75. In addition, the integrated control device 70 is connected to the transmission device 30 via various interfaces.

[0034] For example, the processor 71 registers the identification information received from the collaborative robot 20 via the communication device 75 in the finished product management table, and performs the correctness judgment process of the component. When the component is judged to be "correct", the processor 71 sends an action permission signal to the collaborative robot 20 via the communication device 75. The finished product management table can also be managed by the external control system 90. In this case, the processor 71 transmits the identification information received from the collaborative robot 20 to the external control system 90 via the communication device 75.

[0035] The processor 71 selects an assembly program from a plurality of assembly programs according to the finished product information of the finished product received from the external control system 90 via the communication device 75, and transmits the finished product information to the collaborative robot 20. The finished product information may also be input by the operator via the touch display screen 60 described later.

[0036] (Collaborative Robot 20)

[0037] The collaborative robot 20 is an industrial robot that has safety measures in place to enable it to work with humans in the same space. For example, the collaborative robot 20 may include an industrial robot whose movable range of each joint is physically or software-restricted, an industrial robot that can detect a human approaching and decelerate, or an industrial robot that can detect a human contact and stop.

[0038] like Figure 2 As shown, the collaborative robot 20 has a robot arm 25, and the robot arm 25 has a plurality of joints. As an end effector, the front end of the robot arm 25 is equipped with: a camera (photographing unit) 26 for photographing the components fixed to the workpiece; a code reader (identification information reading unit) 27 for reading identification information such as QR code (registered trademark) and barcode displayed on the workpiece and the components; and an electric screwdriver (screw fastening unit) 28 for fixing the components arranged on the workpiece to the workpiece. Typically, the camera 26 and the code reader 27 are installed in a manner such that their respective optical axes are parallel to the axial direction of the electric screwdriver 28. In most cases, threaded holes are opened or identification information is displayed on the same surface of the workpiece. Therefore, by aligning the axis of the electric screwdriver 28, the optical axis of the code reader 27, and the optical axis of the camera 26 in the above manner, it is possible to avoid having to move the robot arm 25 significantly each time the code reader 27 reads the identification information, the electric screwdriver 28 tightens the screws, and the camera 26 takes pictures of the parts fixed to the workpiece, thereby shortening the operation time and improving the safety of the operator.

[0039] By equipping the robot arm 25 with the camera 26 and the code reader 27, the camera 26 and the code reader 27 can be directed toward the workpiece at various angles, so that the orientation of the workpiece and the components can be flexibly handled. However, they are not necessarily installed on the robot arm 25. As described above, the code reader 27 only needs to be installed at a position where the identification information displayed on the component arranged on the workpiece can be read. Similarly, the camera 26 only needs to be installed at a position where the component fixed to the workpiece can be photographed. For example, the camera 26 and the code reader 27 are installed at a position overlooking the conveyor belt 33 from above. The camera 26 can also serve as the code reader 27.

[0040] The robot arm 25, the camera 26, the code reader 27, and the electric screwdriver 28 are controlled by the robot control device 21. The robot control device 21 has a processor 22, a storage device 23, and a communication device 24.

[0041] The storage device 23 stores a plurality of robot control programs for causing the collaborative robot 20 to perform assembly operations corresponding to the finished product of the assembly object. The robot control program is a program that records a series of actions related to the movement of the finger reference point of the robot arm 25, the screw tightening action of the electric screwdriver 28, and the camera 26 taking pictures of the parts. The robot control program is executed by the processor 22, thereby causing the robot arm 25, the camera 26, and the electric screwdriver 28 to move in the order recorded in the robot control program. The robot control program is associated with a component fixing state judgment program.

[0042] The component fixing state judgment program is a program for judging whether the fixing state of the component fixed to the workpiece is good or not based on the component image captured by the camera 26. The fixing state "good" refers to the state in which the position of the component and the orientation of the component are correct. The component fixing state judgment process can also be performed before the workpiece is fixed to the component as a component configuration state judgment process. Because the position and orientation of the component can be judged before the workpiece is fixed, even in the event of an abnormality, only the position and orientation of the component can be changed, and there is no need to remove the screws, so it is easy to perform the restoration operation and reduce the number of discarded components. In the judgment of the component fixing state implemented after the component is fixed to the workpiece, it can include abnormal judgments related to screw tightening such as forgetting to tighten the screws, loose screws, and screwing in of the screws. By executing the component process state judgment program by the processor 22, for example, the component image when the fixing state of the component fixed to the workpiece is "good" is used as a reference image, and the component image of the component fixed to the workpiece is compared with the reference image, thereby judging whether the fixing state of the component fixed to the workpiece is good or not.

[0043] The collaborative robot 20 is connected to the integrated control device 70 in a communicative manner via the communication device 24. For example, the processor 22 selects a robot control program from a plurality of robot control programs based on the finished product information identifying the finished product received from the integrated control device 70 via the communication device 24. In addition, the processor 22 transmits the good or bad result of the fixing state of the component fixed to the workpiece and the data of the identification information read by the code reader 27 to the integrated control device 70 via the communication device 24.

[0044] The collaborative robot 20 may be configured to be directly connected to an external control system 90 to be described later via the communication device 24 , and may receive the finished product information not via the integrated control device 70 .

[0045] (Transmission device 30)

[0046] like Figure 1 , Figure 2As shown, the conveyor 30 has a conveyor belt 33 on which the workpiece is placed. The conveyor belt 33 is driven by a motor (not shown) controlled by the integrated control device 70, and moves at a preset speed to transport the workpiece placed on the conveyor belt 33 to the working position of the next process. In order to improve the operability of the assembly work of the operator or the cooperative robot 20, the conveyor 30 is equipped with a mechanism (not shown) for positioning the workpiece at the working position of each process.

[0047] The above-mentioned working position, the setting position of the collaborative robot 20, and the standing position of the operator 100 are determined in a manner that constitutes the following relationship. That is, the standing position of the operator 100 is determined so that the working position is included in the working range of the operator's 100 fingers. The setting position of the collaborative robot 20 is determined so that the working position is included in the movable range of its fingers and the standing position of the operator 100 is not included in the movable range of its fingers. As a result, the operator 100 and the collaborative robot 20 can collaborate to perform work on the workpiece placed on the conveyor belt 33. In addition, the fingers of the collaborative robot 20 cannot reach the standing position of the operator 100, so that physical contact with the head and torso of the operator 100 that may cause serious injury can be avoided, thereby improving safety.

[0048] In this embodiment, the conveyor belt 33 includes: a conveyor belt 33A, which sequentially transports the workpiece to the working position of process 1 and process 2; a conveyor belt 33B, which sequentially transports the workpiece transported by the conveyor belt 33A from the working position of process 2 to the working position of process 3 and process 4; a conveyor belt 33C, which sequentially transports the workpiece transported by the conveyor belt 33B from the working position of process 4 to process 5 and process 6; and a conveyor belt 33D, which transports the workpiece transported by the conveyor belt 33C from the working position of process 6 to the working position of process 7. Each conveyor belt 33A, 33B, 33C, and 33D is driven separately. Of course, the conveying device 30 can also be a structure in which each process has an independent conveyor belt.

[0049] (Touch screen 60)

[0050] The touch screen display 60 functions as a display device for displaying various information related to the assembly operation, and also functions as an input device for receiving predetermined input from the operator. Of course, the assembly system 10 can be configured to have a structure having an input device and a display device respectively. Under the control of the integrated control device 70, various setting screens, confirmation screens of the working status of the assembly operation, etc. are displayed on the touch screen display 60. The user can operate on the screen displayed on the touch screen display 60 to change various settings, etc.

[0051] For example, the touch display screen 60 displays Figure 4 The screen showing the status of the assembly work is displayed. Figure 4As shown, the confirmation screen displays the "equipment number" for identifying the assembly system 10, the "product type" showing the type of finished product, the "planned quantity / actual quantity" showing the scheduled number of finished products manufactured on that day and the number of finished products manufactured at the current time point, and the common cycle time of each process. In addition, as the status of the collaborative robot 20, at least one of the three conditions of "original position", "complete operation preparation", and "in operation" is displayed. As the status of the conveyor 30, at least one of the three conditions of "original position", "complete operation preparation", and "in operation" is displayed. Because the assembly system 10 can be restarted and started when the collaborative robot 20 and the conveyor 30 are both in the original position, by displaying the above content on the touch display screen 60, the person in charge of the assembly operation can understand at a glance whether the collaborative robot 20 and the conveyor 30 are configured in the original position. As a result, the above-mentioned startup and restart can be performed quickly. Although this does not directly improve efficiency, it is an element to improve work efficiency.

[0052] On the confirmation screen, information indicating the presence or absence of a workpiece and information indicating the progress of the operation are displayed for each process as information indicating the status of each process. The progress of the operation includes information indicating each process flow of the process such as "operation completed", "workpiece handling completed", "screw tightening operation in progress", "screw tightening completed", "type inspection passed", "assembly inspection passed", etc. The person in charge of the assembly operation can confirm the status of each process displayed on the touch screen 60, and can confirm the progress of the operation of each process and the handling status of the workpiece in real time. Therefore, the overall manufacturing efficiency can be improved by following up with the operator of the process where the operation has not progressed and providing operation guidance, etc.

[0053] The alarm information can be displayed on the confirmation screen. The alarm information includes the date and time when the alarm is generated and the abnormal content. The abnormal content includes, for example, abnormal screw tightening of the collaborative robot 20, abnormal communication between the collaborative robot 20 and the integrated control device 70, and abnormal communication between the integrated control device 70 and the external control system 90. Because the person in charge of the assembly work can quickly confirm which process has an abnormality of what content, measures corresponding to the abnormal content can be taken.

[0054] As the working status of each process, one of the five conditions of "slow", "slightly slow", "normal", "slightly fast", and "fast" can be displayed on the confirmation screen. The above conditions change according to the time difference between the working time and the tact time. For example, "slow (fast)" is displayed when it is slower (faster) than the tact time by more than 10 seconds, slightly slower (slightly faster) is displayed when it is slower (faster) than the tact time by more than 5 seconds and less than 10 seconds, and "normal" is displayed when it is slower or faster than the tact time by less than 5 seconds. The person in charge of the assembly work can confirm the working status of each process displayed on the touch screen 60, and improve the overall manufacturing efficiency by following up on the slow operators and providing guidance on the work.

[0055] (Assembly process)

[0056] Reference Figure 5 , Figure 6 as well as Figure 7 , an example of a finished product assembly operation using the assembly system 10 of this embodiment is described. Figure 5 As shown, the assembly operation of the finished product consists of multiple processes, and here it consists of seven processes. Process 1, process 2, process 5, and process 7 are processes that are performed by the operator 100 alone, and process 3, process 4, and process 6 are processes that the collaborative robot 20 and the operator 100 work together. In each process, the operation flow has been determined. The collaborative robots 20A, 20B, and 20C operate according to the robot control programs corresponding to process 3, process 4, and process 6, respectively.

[0057] like Figure 6 As shown, in process 1, the operator 100A places the base (workpiece) on the conveyor 33 (S11), and affixes a sticker printed with identification information 1 (QR code (registered trademark)) for traceability to the base (S12). When the operator 100A completes the above-mentioned work, he presses the work completion button 37A. As a result, the information that the work of process 1 is completed is input to the integrated control device 70.

[0058] In step 2, the operator 100B sets the component positioning template on the base and arranges the components 1 and 2 along the template (S21, S22). When the operator 100B completes the above work, he presses the work completion button 37B. Thus, the information that the work of step 2 is completed is input to the integrated control device 70.

[0059] In step 3, the robot control device 21A moves the robot arm 25A to a position where the base identification information attached to the base in step 1 can be read by the code reader 27A. The integrated control device 70 controls the code reader 27A to read the base identification information, and registers the read base identification information in the internal data memory, here in the finished product management table (S31).

[0060] Next, the robot control device 21A moves the robot arm 25A to positions where the identification information 1 and 2 of the components 1 and 2 arranged on the base can be read by the code reader 27A. The integrated control device 70 controls the code reader 27A to read the identification information 1 and 2 of the components 1 and 2 in sequence, registers the read identification information 1 and 2 in the finished product management table, and determines whether the components 1 and 2 arranged on the base are correct based on the identification information 1 and 2. When the integrated control device 70 determines that the components 1 and 2 are the correct types of components, it sends an action permission signal to the robot control device 21A. The robot control device 21A controls the robot arm 25A again when receiving the action permission signal (S32).

[0061] The robot control device 21A controls the electric screwdriver 28A to screw parts 1 and 2 to the base (S33), and controls the camera 26A to photograph parts 1 and 2 fixed to the base. The robot control device 21A determines whether the fixing state of parts 1 and 2 fixed to the base is good or not based on the photographed images of parts 1 and 2 (S34). When the robot control device 21A determines that the fixing state of parts 1 and 2 is "good", the robot control device 21A continues to control the robot arm 25A in order to continue the action. On the other hand, when the robot control device 21A determines that the fixing state of parts 1 and 2 is "bad", it stops the control of the robot arm 25A in order to temporarily stop the action of the robot arm 25A, and sends a signal to the integrated control device 70 indicating that the fixing state of parts 1 and 2 is "bad".

[0062] The worker 100C removes the template for component positioning from the base, places the component 3 on the base, and presses the work completion button 37C ( S35 ).

[0063] When the work completion button 37C is pressed, the robot control device 21A moves the robot arm 25A to a position where the identification information 3 of the component 3 arranged on the base can be read by the code reader 27A. The integrated control device 70 controls the code reader 27A to read the identification information 3 of the component 3, registers the read identification information 3 in the finished product management table, and determines whether the component 3 arranged on the base is correct based on the identification information 3. When the integrated control device 70 determines that the component 3 is a component of the correct type, it sends an action permission signal to the robot control device 21A. The robot control device 21A controls the robot arm 25A again when receiving the action permission signal (S36).

[0064] The robot control device 21A controls the electric screwdriver 28A to screw the component 3 to the base (S37), returns the robot arm 25A to the initial position, and sends a work completion signal indicating that the work is completed to the integrated control device 70. In order to keep the work of process 3 within the tact time, in step S37, not all screws are screwed.

[0065] In step 4, the robot control device 21B controls the electric screwdriver 28B to tighten the remaining screws for fixing the component 3 to the base (S41), and controls the camera 26B to photograph the component 3 fixed to the base. The robot control device 21B determines whether the fixing state of the component 3 fixed to the base is good or not based on the photographed component image of the component 3 (S42). When the robot control device 21B determines that the fixing state of the component 3 is "good", the robot control device 21B continues to control the robot arm 25B in order to continue the action. On the other hand, when the robot control device 21B determines that the fixing state of the component 3 is "bad", the robot control device 21B stops the control of the robot arm 25B in order to temporarily stop the action of the robot arm 25B, and sends a signal indicating that the fixing state of the component 3 is "bad" to the integrated control device 70.

[0066] The operator 100D uses a clamp to place the mounting part on the base and presses the work completion button 37D (S43). With the pressing of the work completion button 37D as an opportunity, the robot control device 21B controls the electric screwdriver 28B to tighten the mounting part screws to the base (S44), returns the robot arm 25B to the initial position, and sends a work completion signal to the integrated control device 70.

[0067] like Figure 7 As shown, in step 5, the operator 100E removes the jig from the base and places the component 4 on the base (S51). When the operator 100E completes the above work, he presses the work completion button 37E. Thus, the information that the work of step 5 is completed is input to the integrated control device 70.

[0068] In step 6, the robot control device 21C moves the robot arm 25C to a position where the base identification information attached to the base in step 1 can be read by the code reader 27C. The integrated control device 70 controls the code reader 27C to read the base identification information and registers the read base identification information in the internal data storage, here in the finished product management table (S61).

[0069] Next, the robot control device 21C moves the robot arm 25C to a position where the identification information 4 of the component 4 arranged on the base can be read by the code reader 27C. The integrated control device 70 controls the code reader 27C to read the identification information 4 of the component 4, registers the read identification information 4 in the finished product management table, and determines whether the component 4 arranged on the base is correct based on the identification information 4. When the integrated control device 70 determines that the component 4 is a component of the correct type, it sends an action permission signal to the robot control device 21C. The robot control device 21C takes the receipt of the action permission signal as an opportunity (S62) and controls the robot arm 25C again.

[0070] The robot control device 21C controls the electric screwdriver 28C to screw the component 4 to the base (S63), and controls the camera 26C to photograph the component 4 fixed to the base. The robot control device 21C determines whether the fixing state of the component 4 fixed to the base is good or not based on the photographed component image of the component 4 (S64). When the robot control device 21C determines that the fixing state of the component 4 is "good", the robot control device 21C continues to control the robot arm 25C in order to continue the action. On the other hand, when the robot control device 21C determines that the fixing state of the component 4 is "bad", it stops controlling the robot arm 25C in order to temporarily stop the action of the robot arm 25C, and sends a signal indicating that the fixing state of the component 4 is "bad" to the integrated control device 70.

[0071] The operator 100F places the component 5 on the base and presses the work completion button 37F (S65). The robot control device 21C moves the robot arm 25C to a position where the identification information 5 of the component 5 placed on the base can be read by the code reader 27C, based on which the operator 100F places the component 5 on the base. The integrated control device 70 controls the code reader 27C to read the identification information 5 of the component 5, registers the read identification information 5 in the finished product management table, and determines whether the component 5 placed on the base is correct based on the identification information 5. When the integrated control device 70 determines that the component 5 is a component of the correct type, it sends an action permission signal to the robot control device 21C. The robot control device 21C controls the robot arm 25C again based on the receipt of the action permission signal (S66).

[0072] The robot control device 21C controls the electric screwdriver 28C to screw the component 5 to the base (S67), and controls the camera 26C to photograph the component 5 fixed to the base. The robot control device 21C determines whether the fixing state of the component 5 fixed to the base is good or not based on the photographed component image of the component 5 (S68). When the robot control device 21C determines that the fixing state of the component 5 is "good", the robot control device 21C returns the robot arm 25C to the initial position and sends a work completion signal to the integrated control device 70. On the other hand, when the robot control device 21C determines that the fixing state of the component 5 is "bad", the control of the robot arm 25C is stopped in order to temporarily stop the movement of the robot arm 25C, and a signal indicating that the fixing state of the component 5 is "bad" is sent to the integrated control device 70.

[0073] In process 7, the operator 100G performs a final appearance inspection on the finished product assembled in the previous process 6 (S71), and stores the finished product in the finished product storage rack (S72). When the operator 100G completes the above-mentioned operation, he presses the operation completion button 37G. Thus, the information that the operation of process 7 is completed is input to the integrated control device 70. By pressing the operation completion button 37G, the actual number of manufacturing managed by the integrated control device 70 increases. Thus, it is possible to easily manage the manufacturing performance.

[0074] The integrated control device 70 drives each conveyor belt 33A, 33B, 33C, and 33D of the conveyor device 30 according to a predetermined conveying condition. For example, when the work of a specific process is completed and the work of the subsequent process as the destination of the carry-in is completed and the workpiece has been carried out, the conveyor belt corresponding to the specific process and the conveyor belt corresponding to the subsequent process are driven. In this way, the workpiece that has completed the work in the specific process is transported to the subsequent process. Since each conveyor belt 33A, 33B, 33C, and 33D can be driven separately according to the working conditions of the specific process and the working conditions of the subsequent process, the overall working efficiency can be improved.

[0075] In step 3 and step 6, when the integrated control device 70 determines that the type of the component placed on the workpiece is incorrect, in order to stop the operation of the robot arm 25, the operation permission signal sent to the robot control device 21 is suspended. In addition, a lamp (not shown) installed on the conveyor 30 is lit to notify that an abnormality has occurred, and the content of the abnormality occurrence is displayed on the touch display 60.

[0076] Similarly, in process 3, process 4 and process 6, when the integrated control device 70 receives a signal indicating that the fixing state of a component fixed to the workpiece is "bad" from the robot control device 21, it turns on a lamp (not shown) installed on the conveying device 30 to notify that an abnormality has occurred, and displays the content of the abnormality on the touch display screen 60.

[0077] In this way, when an operation error such as an incorrect component configured on a workpiece or a poor fixing state of a component fixed to a workpiece has occurred, the operation of the collaborative robot 20 (assembly system 10) is stopped and a process of notifying the operator of the abnormality is performed. The operator can be notified of the occurrence of the abnormality as early as possible by lighting the lamp installed on the conveyor 30. In addition, the operator can confirm the abnormal content displayed on the touch display 60 and immediately start the restoration operation. After completing the restoration operation, the operator can restart the assembly operation performed by the assembly system 10 from midway, for example, by pressing the operation completion button 37 of the process where the abnormality has occurred.

[0078] As described above, whenever an abnormality occurs, the cause of the abnormality can be quickly determined by stopping the assembly system 10. This can reduce the number of defective products such as all finished products manufactured in a certain period of time being defective and reduce the waste of parts due to the generation of defective products.

[0079] From the perspective of the manufacturing efficiency of the finished product, it is also possible to not stop the assembly system 10 every time an abnormality occurs, but to give a mark to the workpiece where the abnormality has occurred to avoid performing more assembly operations. For example, a sign indicating that the workpiece has had an abnormality can be prepared in advance, and when an abnormality occurs, the collaborative robot 20 places the above sign on the workpiece. The operator of the downstream process confirms that it is the workpiece that has had an abnormality, and presses the work completion button 37 without performing any operation. Of course, the integrated control device 70 has already grasped which workpiece has had an abnormality, so it is also possible to prevent the collaborative robot 20 configured in the downstream process from operating the workpiece that has had an abnormality. The operator of the final process stores the workpiece that has had an abnormality in the storage rack for defective products. In this way, even if an abnormality occurs, by not stopping the assembly system 10, there is a possibility of improving the manufacturing efficiency of the finished product.

[0080] It is preferable that the operator can choose whether to stop the assembly system 10 when an abnormality occurs. For example, if it is a skilled and reliable assembly operation, the frequency of abnormalities is low, so not stopping the assembly system 10 when an abnormality occurs can improve the overall manufacturing efficiency. On the other hand, if it is a newly established assembly operation, the frequency of abnormalities is high, and it is necessary to immediately understand what kind of abnormality has occurred, so it is better to stop the assembly system 10 when an abnormality occurs.

[0081] In addition, since the correctness of the component is determined at the time when the component is arranged on the workpiece before the component is fixed to the workpiece, even if the component is wrong and the assembly system 10 is stopped, since the component is not fixed to the workpiece, it is sufficient to replace the wrong component with the correct component, and the stopped assembly system 10 can be quickly restarted. That is, by determining the correctness of the component before the component is fixed to the workpiece, compared with the case where the correctness of the component is determined after the component is fixed to the workpiece, the restoration work when the component is wrong can be made easier, thereby improving the work efficiency.

[0082] Similarly, since the fixing state of the component already fixed to the workpiece is determined before arranging other components, if the fixing state of the component is not good and the assembly system 10 is stopped, the operator only needs to re-perform the fixing operation of the bad component, and the stopped assembly system 10 can be quickly restarted. Of course, although it is also conceivable that the fixing state of the component is not good and the component is discarded and a new component has to be fixed, even in this case, only the component with the bad fixing state needs to be discarded, and it can be avoided that other components have to be discarded.

[0083] In this way, the type of components is checked every time a component is placed on a workpiece, and the fixing state of the components is checked every time a component is fixed to a workpiece. This can shorten the time that the assembly system 10 is stopped due to inspection failures and minimize the discarding of components.

[0084] According to the assembly system 10 of this embodiment, each process can be inspected by equipping the robot arm 25 with the camera 26 and the code reader 27. Moreover, since the inspection is automatically performed without the operator's glasses, the inspection quality can be kept constant compared to the case where the operator 100 performs the inspection.

[0085] If the finished product is difficult to observe the components in the assembled state, it will take a long time to inspect the components installed in the finished product at once. However, by inspecting each process, the time for inspecting one component can be shortened and the inspection efficiency can be improved.

[0086] Instead of setting a work process for only inspection, the process performed by the collaborative robot 20 and the operator 100 in cooperation includes the inspection work. During the inspection by the collaborative robot 20, the operator 100 can prepare for the next work, so the inspection time of the collaborative robot 20 is not wasted, and the assembly work and inspection work of the finished product can be efficiently performed, which can improve the manufacturing efficiency of the finished product. Of course, since there is no need to set up a process for inspection, there is no need to ensure space for the process for inspection, and the assembly system 10 can be constructed in a space-saving manner.

[0087] Because each process is inspected, the occurrence of an abnormality can be detected quickly, and the assembly system 10 can be stopped and measures can be taken before further abnormalities occur. As a result, the frequency of abnormalities can be suppressed, and the discarding of parts can also be suppressed. This effect is particularly evident in the assembly operation of finished products with multiple processes. For example, for a system that is inspected in the final process, even if an abnormality is found in the final process and the system is temporarily stopped, there is a high possibility that the same abnormality will occur in all workpieces from the process where the abnormality occurred to the final process. Therefore, there are many workpieces that are the objects of restoration operations such as disassembling parts, replacing, and re-fixing. As in the present embodiment, inspections can be performed in each process, thereby stopping the assembly system 10 at the time when the abnormality occurs, thereby avoiding the above situation.

[0088] In addition, in the present embodiment, the camera 26 is used to photograph the components after they are fixed to the workpiece, and based on the photographed component image, it is possible to determine whether the fixing state of the components fixed to the workpiece is good or not (the position and orientation of the components). This judgment may include abnormalities associated with screw tightening (forgot to tighten, loose, screwed in). Thus, the possibility of operational defects occurring during the component fixing operation performed by the electric screwdriver 28 can be reduced, and the quality can be ensured without relying on the proficiency of the operator. In addition, it is also possible to determine whether the component itself is a good product or a defective product based on the component image of the component arranged on the workpiece.

[0089] In this embodiment, the collaborative robot 20 determines whether the fixing state of the component is good or not based on the component image, but the component image can also be provided from the robot control device 21 to the integrated control device 70, and the integrated control device 70 determines whether the fixing state of the component is good or not. In addition, the integrated control device 70 determines whether the component type is correct or not based on the identification information, but the robot control device 21 can also implement it.

[0090] In addition, the assembly system 10 of this embodiment has a code reader 27 and a camera 26 to check the correctness of the component type and the quality of the component fixing state. However, if at least one of the inspections can be performed, the risk of defective products flowing out can be reduced and the efficiency of the assembly operation can be improved. Therefore, the assembly system 10 may also have one of the code reader 27 and the camera 26.

[0091] In addition, in the assembly system 10 of the present embodiment, the workpiece is placed on the conveyor belt 33, and when the work of each process is completely completed, it is transported to the work position of the next process, but the structure of the conveyor device 30 is not limited to this. For example, it is also possible to have a structure in which the operator manually moves the conveyor belt 33. In addition, the conveyor device 30 may also have a structure having a plurality of work tables (platforms) for placing the workpiece, and each work table is independently driven.

[0092] In addition, in the assembly system 10 of the present embodiment, from the viewpoint of safety and applicability, a collaborative robot 20 is used, but as a device cooperating with the operator 100, a general industrial robot may also be used. In addition, if only simple operations such as screw tightening operations are performed, the device cooperating with the operator 100 may use an operating machine other than a robot such as a cylinder. In the case of using an action mechanism other than the collaborative robot 20, it is preferred to provide a partition wall or a safety fence to physically prevent the action mechanism from contacting the operator. In this way, the assembly system 10 constructed can also achieve the same effect as the present embodiment.

[0093] Several embodiments of the present invention have been described, and these embodiments are shown as examples, and their purpose is not to limit the scope of the invention. These embodiments can be implemented in various other ways, and various omissions, substitutions, and changes can be made without exceeding the scope of the main purpose of the invention. These embodiments and their variations are included in the scope and main purpose of the invention, and similarly, they are also included in the invention recorded in the claims and their equivalents.

[0094] Description of Reference Numerals

[0095] 10…assembly system, 20…collaborative robot, 21…robot control device, 23…robot arm, 25…camera, 27…code reader, 29…electric screwdriver, 30…transmission device, 33…conveyor belt, 37…finish button, 60…touch screen, 70…integrated control device, 71…processor, 73…storage device, 75…communication device, 90…external control system.

Claims

1. An assembly system for assembling a finished product while sequentially arranging and fixing a plurality of types of components to a workpiece, wherein: have: Collaborative robots work with operators; an identification information reading section that reads identification information displayed on the component arranged on the workpiece after arrangement and before fixation; a photographing unit for photographing the component disposed on the workpiece after being disposed and before being fixed; as well as A control device, based on the read identification information and the configuration state including the position of the component and the orientation of the component obtained from the image of the component taken, determines the type of the component configured on the workpiece and the correctness of the configuration state, and controls the collaborative robot according to the correctness result, and when it is determined that the type of the component configured on the workpiece and the configuration state are correct, controls the collaborative robot to fix the component; The operator is responsible for the configuration of the components. The collaborative robot is responsible for fixing the components configured by the operator. When the control device determines that the type and the arrangement state of the component arranged on the workpiece are correct, the control device allows the cooperative robot to start the fixing operation of the component.

2. The assembly system according to claim 1, wherein: The identification information reading unit is installed on the collaborative robot.

3. The assembly system according to claim 1 or 2, wherein: The photographing unit further photographs the component fixed to the workpiece. The action of the collaborative robot continues or stops according to the good or bad result of the fixing state of the component fixed to the workpiece, and the good or bad result of the fixing state of the component fixed to the workpiece is a result obtained based on the image of the component taken.

4. The assembly system according to claim 3, wherein: The collaborative robot determines whether a fixing state of the component fixed to the workpiece is good or not based on the image of the component and sends the good or not result to the control device.

5. The assembly system according to claim 3, wherein: The assembly system also has a display unit, which displays at least one of the correct or incorrect result, the good or bad result, the type of the finished product, the manufacturing quantity of the finished product, and the status of the collaborative robot.

6. The assembly system according to claim 1 or 2, wherein: The collaborative robot has a screw fastening portion, The control device allows the cooperative robot to start the screw tightening operation when the type and the arrangement state of the component arranged on the workpiece are correct as a result of the correctness.

7. The assembly system according to claim 1 or 2, wherein: When the control device determines that the type and the arrangement state of the component arranged on the workpiece are wrong, the control device does not allow the cooperative robot to start the fixing operation of the component.

8. The assembly system according to claim 1 or 2, wherein: The assembly system further comprises a conveying device which supports the workpiece so as to enable the workpiece to be movable.

9. The assembly system according to claim 8, wherein: The cooperative robot and the worker's standing positions are provided on both sides of the conveyor, and the conveyor is arranged at a position where a movable range of fingers of the cooperative robot overlaps with a working range of the worker.

10. The assembly system according to claim 8, wherein: The control device controls the conveying device to move the workpiece when receiving a signal indicating completion of the work input by the operator or receiving a signal indicating completion of the work from the cooperative robot.

11. The assembly system according to claim 1 or 2, wherein: The control device registers the read identification information in an internal data memory or sends it to an external data server.

12. The assembly system according to claim 1 or 2, wherein: The collaborative robot has a storage unit storing a plurality of action programs. The control device is connected to an external system in a communicable manner, and instructs the cooperative robot to use one of the plurality of action programs based on finished product information identifying the finished product received from the external system.

13. The assembly system according to claim 1 or 2, wherein: The assembly system includes an input unit for receiving input of finished product information identifying the finished product from an operator. The collaborative robot has a storage unit storing a plurality of action programs. The control device instructs the cooperative robot to perform one of the plurality of operation programs based on the input finished product information.

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